Best Dual Pulley Setup for Audi 3.0T (S4, S5, A6, A7, SQ5)
Unleash full supercharged power — it’s time to go dual. Intro: Dual Pulley = Double the Power Potential The Audi 3.0T engine…
Unleash full supercharged power — it’s time to go dual.
Intro: Dual Pulley = Double the Power Potential
The Audi 3.0T engine is already known in the enthusiast world as one of the most tuner-friendly platforms out there. But while most casual owners slap on a single pulley, intake, and call it a day, real power junkies know where the real sauce is: dual pulley.
The dual pulley setup transforms the Eaton TVS1320 blower from tame to terrifying. It spins faster, makes more boost, and with the right supporting mods? It’ll embarrass way faster (and more expensive) cars with ease.
In this in-depth guide, we’re breaking down the best dual pulley setup for Audi 3.0T supercharged engines. We’ll cover what it is, how it works, what you need to run it right, and what brands and parts actually deliver — with Amazon, AliExpress, and GermanCarMods links to make your build simple.
What Is a Dual Pulley Setup?
If you’re new to modding the 3.0T, here’s the basic idea:
- The upper pulley sits on the supercharger snout. Shrinking this pulley increases how fast the blower spins.
- The lower pulley sits on the crankshaft. Increasing its diameter spins the blower even faster, because it drives the entire belt system harder.
Run them together? And you get one of the most cost-effective and reliable power setups in the German tuning world.
Why Go Dual Pulley Instead of Just Upper?
Good question. While the upper pulley alone gets you about +3 PSI and ~60whp, adding the lower pulley lets you:
- Gain up to +7 PSI over stock
- See real-world power increases of +80–120whp
- Make use of ethanol blends (E40), water-meth, and aggressive tuning
- Pull harder to redline, without falling off
- Make your S4/S5 feel like a legit RS7 on the freeway
If you’re chasing numbers, dual pulley is where the 3.0T becomes a monster.
Which Audi Models Can Run This Setup?
Any model with the supercharged 3.0T V6 engine can safely run a dual pulley setup:
- Audi S4 B8/B8.5 (2010–2016)
- Audi S5 B8.5 (2013–2017)
- Audi A6 C7 3.0T (2012–2018)
- Audi A7 C7 3.0T (2012–2018)
- Audi SQ5 3.0T (2014–2017)
If you’re driving any of these and haven’t done dual pulley yet — you’re leaving a whole second personality locked behind software.
Core Parts for a Dual Pulley Build
Let’s get into the meat of it.
🔩 1. Upper Pulley (Supercharger Pulley)
Usually 57.5mm to 57.3mm in size (OEM is 63mm). It’s pressed onto the blower shaft and requires a removal/install tool.
- IE 57.5mm Pulley – Amazon
- CTS Turbo Upper Pulley – AliExpress
Expect +3 PSI alone from this mod, +50–60whp with a tune.
⚙️ 2. Lower Crank Pulley
This is what separates men from boys. It mounts to the OEM crank hub or replaces it entirely (depending on the brand).
Popular sizes:
- 179mm: Conservative, mild dual
- 187mm: Most balanced, best for 93 or E40
- 196mm: Aggressive, must have heat mods
Recommended Brands:
- 034Motorsport: Complete kits
- Integrated Engineering: Lightweight
- JHM: Hardcore, proven performance
🔗 Buy 034 Dual Pulley Kit
🔗 187mm Budget Pulley – AliExpress
🧵 3. Correct Belt Length
Bigger pulleys = longer belt. Here’s a general guide:
| Crank Pulley | Belt Size |
|---|---|
| 179mm | 6PK1300 |
| 187mm | 6PK1315–1320 |
| 196mm | 6PK1330–1340 |
Stick to Gates or Continental for quality and grip. Belt slip will kill performance fast.
Supporting Mods You Absolutely Need
Dual pulley adds serious stress and heat. If you don’t support it, your car’s gonna hate you.
❄️ 1. Upgraded Heat Exchanger
The stock HX can’t handle the extra heat. After just a few pulls, your blower IATs skyrocket and you’re deep in heat soak.
Top options:
Internal Link:
👉 Best Heat Exchanger Upgrade for Audi 3.0T
🔥 2. Colder Spark Plugs
Stock plugs can’t handle the detonation at high boost. Go at least 1 step colder.
- NGK BKR8EIX gapped to 0.028
- 🔗 Buy on Amazon
Internal Link:
👉 Best Spark Plugs for Audi A7
💨 3. Intake and Exhaust Mods
More boost = more airflow needed. The stock intake and exhaust are bottlenecks.
- Intakes: Roc-Euro, IE, CTS
- Downpipes: High-flow or catless
- Catback: Not necessary, but helps and sounds better
Internal Links:
👉 Best Intake for Audi S5 B8.5
👉 Best Downpipes for Audi A7
🧠 4. ECU Tune Built for Dual Pulley
Your car’s computer needs to know what’s up.
Top tunes:
- 034Motorsport Stage 2+
- Integrated Engineering Dual Pulley Tune
- EPL Dual Pulley (flash at home)
- APR Stage 2+ (dealer-only)
Pro Tip: If you plan on E40 or WMI, go with IE or EPL — they’re more flexible.
Expected Gains: Real Dyno-Proven Numbers
Let’s cut the fluff:
| Setup | Fuel | WHP Est. |
|---|---|---|
| Single Pulley + Tune | 91/93 | 410–430 |
| Dual Pulley + 93 Tune | 93 | 460–480 |
| Dual Pulley + E40 + HX | E40 | 490–510 |
| Dual Pulley + E40 + WMI | E40+WMI | 520–540 |
That’s RS-level power in a $15K daily. No turbos. No fuel system. No B.S.
Install Guide: Wrench Level 7/10
This isn’t hard if you’re not dumb. But you do need tools.
🛠️ What You Need:
- Pulley removal tool (IE/034)
- Impact wrench or breaker bar
- Serpentine belt diagram
- Torque wrench (crank bolts matter)
👇 Install Process:
- Upper pulley: Heat new one, press-fit on
- Crank pulley: Remove OEM, bolt new hub/ring
- Install new belt, route properly
- Flash ECU with new software
- Log it. Monitor IATs and timing.
Time: 4–6 hours
Shop install cost: $500–600
Is It Daily-Drivable? Absolutely.
This setup is shockingly reliable when cooled correctly.
✅ Still gets 20–25 MPG on highway
✅ No need for fueling unless you’re on E85
✅ Blower screams like it’s angry at the road
✅ No limp mode, no CEL if tuned properly
BUT… if you skip your heat exchanger or run bad gas? You’ll be misfiring, limping, and crying to the forums in no time.
FAQ – Dual Pulley Audi 3.0T
Q: Do I need a DSG or TCU tune?
A: If you’re pushing full E40 + WMI, yes. Otherwise optional.
Q: Can I just do the crank pulley first?
A: Technically yes, but you’ll still need the tune and cooling. Most go upper first.
Q: Will this void my warranty?
A: Yes. This is not a dealership-friendly mod. You mod it, you own it.
Quick Links to Build Your Setup
- 🔩 IE Supercharger Pulley – Amazon
- ⚙️ CTS Crank Pulley – AliExpress
- ❄️ Mishimoto Heat Exchanger – Amazon
- 🔧 Stage 2 Tuning Guide – GermanCarMods
Final Words: Don’t Half-Send It
A dual pulley setup on the 3.0T doesn’t just make you faster — it transforms your entire driving experience. It’s the kind of mod you’ll feel every time you go WOT, every freeway pull, every gear change. It’s the mod that makes people say “Bro… what’s under the hood?”
So if you’re ready to push your S4, A6, or A7 past the casual stage and into real street weapon territory — this is your setup.
Send it right. Or don’t send it at all.